Electromagnetic valve for controlling a fuel injection of an internal combustion engine

ABSTRACT

The present invention relates to a solenoid valve for controlling a fuel injector of an internal combustion engine, including an electromagnet ( 29 ), a movable armature featuring an armature plate ( 28 ) and an armature pin ( 27 ), as well as a control valve member ( 25 ) which is moved with the armature and cooperates with a valve seat ( 24 ), for opening and closing a fuel discharge passage ( 17 ) of a control pressure chamber ( 14 ) of the fuel injector ( 1 ), the armature plate ( 28 ) being supported on the armature pin ( 27 ) in such a manner that it is slidably movable in the closing direction of the control valve member ( 25 ) under the action of its inertial mass, against the elastic force of a return spring ( 35 ) that acts upon the armature plate ( 28 ); and including a hydraulic damping device which permits damping of a post-oscillation of the armature plate ( 28 ) during its dynamic sliding on the armature pin ( 27 ). To facilitate the assembly and reduce a disadvantageous post-oscillation process of the armature plate, it is proposed for the return spring ( 35 ) to be braced, with its end ( 62 ) facing away from the armature plate ( 28 ), against a supporting piece ( 50 ) which is mounted on and moved with the armature pin ( 27 ) and which, at the same time, constitutes a part ( 57 ) of the damping device.

FIELD OF THE INVENTION

[0001] The present invention relates to a solenoid valve for controlling a fuel injector of an internal combustion engine according to the definition of the species in claim 1.

[0002] Such a solenoid valve, which is known, for example, from German Patent Application DE 197 08 104 A1, is used for controlling the fuel pressure in the control pressure chamber of a fuel injector, for example, of an injector of a common-rail injection system. The movement of a valve plunger, which is used to open or close an injection orifice of the fuel injector, is controlled via the fuel pressure in the control pressure chamber. The known solenoid valve features an electromagnet located in a housing part, a movable armature as well as a control valve member which is moved with the armature and acted upon by a closing spring in the closing direction and which cooperates with a valve seat of the solenoid valve, thus controlling the fuel discharge from the control pressure chamber. A known disadvantage of the solenoid valves consists in the so-called armature bounce. When the magnet is de-energized, the closing spring of the solenoid vale accelerates the armature and, with it, the control valve member toward the valve seat to close a fuel discharge passage from the control pressure chamber. The impact of the control valve member on the valve seat can cause the control valve member to oscillate and/or bounce at the valve seat in a disadvantageous manner, impairing the control of the injection process.

[0003] In the solenoid valve known from German Patent Application DE 197 08 104 A1, therefore, the armature has a two-part design including an armature pin and an armature plate slidably supported on the armature pin so that when the valve control member hits the valve seat, the armature plate continues to move against the elastic force of a return spring. Subsequently, the return spring restores the armature plate to its original position at a stop of the armature pin. Due to the two-part design of the armature, the effective mass to be decelerated and, consequently, the bounce-causing kinetic energy of the armature striking the valve seat are indeed reduced; however, the armature plate can oscillate in a disadvantageous manner on the armature pin after the closure of the solenoid valve. Since it is a only after the armature plate has stopped oscillating that a defined injection quantity can be produced again by controlling the solenoid valve, measures are required to reduce the post-oscillation of the armature plate. This is required, in particular, to obtain short intervals between, for example, a preinjection and a main injection.

[0004] To solve this problem, it is proposed in German Patent Application DE 197 08 104 A1 to use an overtravel stop which limits the path length by which the armature plate can slide on the armature pin. The overtravel stop is immovably mounted in the housing of the solenoid valve between the armature plate and a slide piece which guides the armature pin. When the armature plate approaches the overtravel stop, a hydraulic damping chamber is formed between the facing sides of the armature plate and of the overtravel stop. The fuel contained in the damping chamber produces a force which counteracts the movement of the armature plate. Therefore, the post oscillation of the armature plate is strongly damped. Using the overtravel stop, the post-oscillation time of the armature plate is indeed shortened; however, the required overtravel distance of the armature plate has to be adjusted during the assembly of the solenoid valve in the housing of the solenoid valve. This requires a costly modification of the manufacturing process because the manufacturing facilities have to be retrofitted accordingly.

ADVANTAGES OF THE INVENTION

[0005] The solenoid valve according to the present invention having the characterizing features of claim 1 avoids the disadvantages occurring in the related art. Advantageously, the armature including the armature plate, armature pin, return spring and the overtravel stop can be preassembled outside of the assembly line of the fuel injector and the required sliding path of the armature plate on the armature pin can be adjusted outside of the housing of the fuel injector. Subsequently, the preassembled armature assembly can then be fitted into the housing of the solenoid valve. No costly modification of the assembly line is required. Moreover, because the return spring which, in its resting position, presses the armature plate against a first stop on the armature pin with a first end, is not supported immovably with the second end in the housing of the solenoid valve but braced against a supporting piece, which is secured to and moved with the armature pin, it is advantageously achieved that the return spring does not counteract the closing spring of the solenoid valve which acts upon the armature pin. Therefore, the closing spring of the solenoid valve can be designed to have a lower spring tension force. Since the return spring no longer counteracts the closing spring, the return spring no longer influences the dynamic performance of the armature pin.

[0006] Advantageous exemplary embodiments and refinements of the present invention are made possible by the features contained in the dependent claims.

[0007] It is particularly advantageous for the armature pin to be slidably supported in an opening of a slide piece which is immovably mounted in the housing of the solenoid valve and for the slide piece side facing the armature plate to be provided with a recess in which is located the supporting piece, which is secured to the armature pin, the outer contour of the supporting piece being spaced apart from the inner contour of the recess by a gap. With these measures, it is achieved that a hydraulic damping chamber is formed through the approximation of the supporting piece to the inner wall of the recess of the slide piece and that the fuel which is compressed between the supporting piece and the recess additionally damps the impact of the control valve member which is coupled to the armature pin.

DRAWINGS

[0008] Exemplary embodiments of the present invention are depicted in the drawing and will be explained in the following description.

[0009]FIG. 1 is a cross-section through the upper part of a fuel injector known from the related art, including a solenoid valve;

[0010]FIG. 2 shows a subsection of the solenoid valve known from the related art featuring an overtravel adjusting disk;

[0011]FIG. 3 represents a cross-section through the armature assembly with slide piece according to a first exemplary embodiment of the present invention;

[0012]FIG. 4 is a cross-section through the armature assembly with slide piece according to a second exemplary embodiment of the present invention;

[0013]FIG. 5 depicts a cross-section through the armature assembly with slide piece according to a third exemplary embodiment of the present invention.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0014]FIG. 1 shows the upper part of a fuel injector 1 known from the related art which is intended for use in a fuel-injection system equipped with a high-pressure fuel accumulator which is continuously supplied with high-pressure fuel via a high-pressure feed pump. Fuel injector 1 shown has a valve housing 4 featuring a longitudinal bore 5 in which is located a valve plunger 6 which, via one of its ends, acts upon a valve needle which is disposed in a nozzle body which is not shown. The valve needle is located in a pressure chamber which is supplied with fuel at high pressure via a pressure bore 8. During an opening stroke of valve plunger 6, the valve needle is lifted against the closing force of a spring by the high fuel pressure in the pressure chamber which continuously acts upon a pressure shoulder of the valve needle. Via an injection orifice, which is then connected to the pressure chamber, the fuel is injected into the combustion chamber of the internal combustion engine. By lowering valve plunger 6, the valve needle is pressed into the valve seat of the fuel injector in the closing direction, completing the injection process.

[0015] As is visible in FIG. 1, valve plunger 6 is guided in a cylinder bore 11 at its end facing away from the valve needle, the cylinder bore being provided in a valve piece 12 which is inserted in valve housing 4. In cylinder bore 11, end face 13 of valve plunger 6 encloses a control pressure chamber 14 which is connected to a high-pressure fuel connection via an inlet passage. The inlet passage is essentially designed in three parts. A bore, which runs radially through the wall of valve piece 12 and whose inside walls form an inlet throttle 15 over a part of their length, is permanently connected, via a fuel filter which is inserted in the inlet passage, to an annular space 16 which surrounds the valve piece on the peripheral side and which, in turn is permanently connected to the high-pressure fuel connection of a connection piece 9 which is able to be screwed into valve housing 4. Annular space 16 is sealed from longitudinal bore 5 via a sealing ring 39. Via inlet throttle 15, control pressure chamber 14 is subjected to the high fuel pressure present in the high-pressure fuel accumulator. Coaxially to valve plunger 6, a bore branches off from control pressure chamber 14, the bore running in valve piece 12 and forming a fuel discharge passage 17 which is provided with a discharge throttle 18 and empties into a relief chamber 19 which is connected to a low-pressure fuel connection 10 which, in turn, is connected to the fuel return of fuel injector 1 in a manner not shown. The outlet of fuel discharge passage 17 from valve piece 12 occurs in the region of a conically countersunk part 21 of the external end face of valve piece 12. Valve piece 12 is firmly clamped to valve housing 4 in a flange region 22 by way of a threaded member 23.

[0016] In conical part 21, a valve seat 24 is formed with which cooperates a control valve member 25 of a solenoid valve 30 controlling the fuel injector. The control valve member 25 is coupled to a two-part armature in the form of an armature pin 27 and an armature plate 28, the armature cooperating with an electromagnet 29 of the solenoid valve 30. Solenoid valve 30 further includes a housing part 60 which accommodates the electromagnet and which is firmly connected to valve housing 4 via threaded connecting means 7. In the known solenoid valve, armature plate 28 is supported on armature pin 27 in such a manner that it is dynamically movable under the action of its inertial mass against the preload force of a return spring 35 and, in the resting condition, is pressed by means of this return spring against a crescent disk 26 which is secured to armature pin 27. With its other end, return spring 35 is braced, immovably relative to the housing, against a flange 32 of a slide piece 34 which guides armature pin 27 and is firmly clamped in the valve housing with this flange between a spacer disk 38 placed on valve piece 12 and threaded member 23. Armature pin 27 and, with it, armature disk 28 and control valve member 25 which is coupled to the armature pin, are permanently acted upon by a closing spring 31 which is immovably supported relative to the housing so that control valve member 25 normally bears against valve seat 24 in the closed position. When the electromagnet is energized, armature plate 28 is attracted by the electromagnet and, in the process, discharge passage 17 is opened toward relief chamber 19. Between control valve member 25 and armature plate 28, an annular shoulder 33 is located on armature pin 27, the annular shoulder striking against flange 32 when the electromagnet is energized, thus limiting the opening stroke of control valve member 25. To adjust the opening stroke, use is made of spacer disk 38, which is located between flange 32 and valve piece 12. In other known solenoid valves, the opening stroke of control valve member 25 is adjusted via a stop element located between armature plate 28 and electromagnet 29.

[0017] The opening and the closure of the fuel injector is controlled by solenoid valve 30 as described below. Armature pin 27 is constantly loaded by closing spring 31 in the closing direction so that when the electromagnet is de-energized, control valve member 25 engages on valve seat 24 and control pressure chamber 14 is closed toward relief side 19 so that there, the high pressure which is also present in the high-pressure fuel accumulator builds up rapidly. Via the surface of end face 13, the pressure in control pressure chamber 14 produces a closing force on valve plunger 6 and, consequently, on the valve needle connected thereto, which is greater than the forces which, on the other hand, act in the opening direction because of the prevailing high pressure. When control pressure chamber 14 is opened toward relief side 19 by the opening of the solenoid valve, the pressure in the small volume of control pressure chamber 14 is reduced very quickly since the control pressure chamber is decoupled from the high pressure side via inlet throttle 15. As a consequence, the force from the high fuel pressure present at the valve needle which acts upon the valve needle in the opening direction predominates so that the valve needle is moved upward and, in the process, the at least one injection orifice is opened for injection. However, when solenoid valve 30 closes fuel discharge passage 17, the pressure in control pressure chamber 14 can be built up again by the subsequent flow of fuel so that the original closing force is present, closing the valve needle of the fuel injector.

[0018] During the closure of the solenoid valve, closing spring 31 presses armature pin 27, together with control valve member 25, abruptly against valve seat 24. A disadvantageous bounce or post-oscillation of the control valve member occurs because the impact of the armature pin on the valve seat causes an elastic deformation thereof which acts as an energy store, part of the energy being transferred to the control valve member again which then bounces from valve seat 24 together with the armature pin. Therefore, the known solenoid valve shown in FIG. 1 uses a two-part armature having an armature plate 28 which is decoupled from armature pin 27. In this manner, it is indeed possible to reduce the overall mass which strikes the valves seat, however, armature plate 28 can subsequently oscillate in a disadvantageous manner. For this reason, an overtravel adjusting disk 70 is provided in the known solenoid valve between armature plate 28 and slide sleeve 34, as shown in FIG. 2. Overtravel adjusting disk 70 limits the sliding path of armature plate 28 on armature pin 27 to dimension d. The post-oscillation of armature plate 28 is reduced by overtravel adjusting disk 70, and armature plate 28 returns faster to its original position at stop 26. Spacer disk 38, slide piece 34, and overtravel adjusting disk 70 are immovably clamped in the housing of the solenoid valve. In the case of the solenoid valves known from the related art, therefore, overtravel distance d has to be adjusted during assembly in the housing of the solenoid valve via the thickness of the overtravel adjusting disk used. In some embodiments, however, the thickness of the overtravel adjusting disk influences also the distance of armature plate 28 from electromagnet 29. This is the case, for example, if the end face of solenoid valve housing 60 is braced against flange 32. In these cases, an inner disk and an outer disk are used in lieu of the overtravel adjusting disk. Thus, the manufacture of the solenoid valve and of the fuel injector provided with the solenoid valve is quite costly and complicated. A preadjustment of the overtravel distance or of the sliding path d of armature plate 28 on armature pin 27 outside of solenoid valve housing 60 is not possible.

[0019]FIG. 3 shows a first exemplary embodiment of the solenoid valve according to the present invention. Depicted are only slide piece 34 and the armature including armature pin 27, armature plate 28 and return spring 35. Identical parts are provided with the same reference symbols. The armature assembly shown can, for example, be inserted into solenoid valve housing 60 shown in FIG. 1. An important difference from the system shown in FIG. 2 consists in that a supporting piece 50, which is firmly connected to armature pin 27, is provided in place of the overtravel adjusting disk which is immovably mounted in the housing of the solenoid valve. For example, a disk which is secured to armature pin 27 can be provided as the supporting piece. In the exemplary embodiment of FIG. 3, the disk is slid onto armature pin 27 and, subsequently, firmly connected to the armature pin, for example, by welding or adhesive bonding. Other fastening types, such as shrink-fitting, are also possible. In a preferred exemplary embodiment, supporting piece 50 is welded to armature pin 27 on side 59 facing away from the armature plate. Weld 51 on lower side 59 of supporting part 50 is visible in FIG. 1.

[0020] Return spring 35 is braced against armature plate 28 with one end 61 and, with its other end 62, against the side 57 of supporting 50 facing armature plate 28.

[0021] During the manufacture of the armature assembly, initially, armature plate 28 is slid onto armature pin 27 until the armature plate butts against a head 55 of the armature pin. Head 55 replaces crescent disk 26 in FIGS. 1 and 2 and, like the crescent disk, is used as a stop for the armature plate. Subsequently, return spring 25 is slid onto guide stub 65 of armature plate 28 until it bears against the armature plate with end 61. Finally, disk-shaped supporting piece 50 is slid onto armature pin 27 so far that required overtravel distance d remains between facing sides 57 and 58 of supporting piece 50 and of guide stub 65. Finally, supporting piece 50 is secured to armature pin 27 in this position. Subsequently, the armature assembly including armature pin 27, armature plate 28, return spring 35 and supporting piece 50 is inserted into slide piece 34. In the process, armature pin 27 is inserted into a central bore 68 of slide piece 34. Slide piece 34 can already be clamped with flange 36 in housing 60 of the solenoid valve. Unlike the known system shown in FIG. 2, no annular shoulder 33 which limits the opening stroke by butting against slide piece 34 is provided, as is also visible in FIG. 3. Instead, the opening travel is limited by armature pin head 55 striking against the electromagnet or a projection of the electromagnet. This is necessary to allow armature pin 27 in FIG. 3 to be inserted into slide piece 34 from above. As is also discernible in FIG. 3, the side of slide piece 34 facing supporting piece 50 has a recess 52 with which the supporting piece engages.

[0022] In the installed condition, as already described in detail above, lower end 67 of armature pin 27 acts upon control valve member 25 which, when the electromagnet is de-energized, is pressed against valve seat 24 by the closing force of spring 31. In this position, side 59 of supporting 50 facing away from armature plate 28 as well as weld 51 are spaced apart from the inner wall of recess 52 by a gap. By this measure, supporting piece 50, which is moved with the armature pin, is prevented from butting against the inner wall of recess 52 since such butting could result in that control valve member 25 does not make contact on valve seat 24. Therefore, recess 52 can be designed in such a manner that it can also accommodate weld 51 and is always spaced a little bit apart therefrom.

[0023] As is also visible in FIG. 3, a hydraulic damping chamber is formed through the approximation of lower side 59 of supporting piece 50 to the inner wall of cylindrical recess 52 of slide piece 34 during the closure of the solenoid valve. The fuel which is compressed between supporting piece 50 and recess 52, and which can escape only laterally through the gap, advantageously damps the impact of armature pin 27 and of control valve member 25 coupled thereto on valve seat 24.

[0024] As soon as armature pin 27 and valve control member 25 make contact on valve seat 24, armature plate 28 slides downward against the elastic force of return spring 25 because of its inertial mass. Between lower end face 58 of armature plate 28 facing supporting piece 50 and side 57 of supporting piece 50 facing armature plate 28, which supporting piece does no longer move at that moment, a further hydraulic damping chamber forms through the approximation of armature plate 28. The fuel contained in the gap between armature plate 28 and supporting piece 50 produces an opposing force which counteracts the motion of the armature plate. Thus, the compensating movement of armature plate 28 is limited by the position of the supporting piece on armature pin 27, resulting in a reversal of motion upon previous damping and, consequently, in a reduction of the post-oscillation process.

[0025]FIG. 4 shows a further exemplary embodiment of the present invention which differs from that shown in FIG. 3 in that supporting piece 50 is secured to armature pin 27 in a positive-locking manner. In this exemplary embodiment, supporting piece 50 is designed as a crescent disk which features an open cutout 56 and is laterally slid onto the armature pin with the open end. Armature pin 27 has a circumferential groove 54 with which the inner contour of cutout 56 of crescent disk 50 engages in a positive-locking manner. Crescent disk 50, which is slid onto the armature pin, is secured in its position perpendicularly to the armature pin by recess 52 of slide piece 34. The path length by which the armature pin is moved in axial direction during the opening and the closure of the solenoid valve is markedly smaller than the depth of recess 52 so that crescent disk 50 cannot inadvertently slip out of its position on armature pin 27.

[0026]FIG. 5 shows a third exemplary embodiment representing a modification of the exemplary embodiment shown in FIG. 4. In this exemplary embodiment, supporting piece 50 is designed as a crescent disk again which is slid onto a section 72 of armature pin 27 via the open end (not shown). Section 72 is designed to have a smaller diameter than the diameter of the section of armature pin 27 which is guided in slide piece 34 and delimited therefrom by a circumferential shoulder 71. Return spring 35 is braced against armature plate 28 with one end. With the other end, return spring 35 presses crescent disk 50 against circumferential shoulder 71 formed on armature pin 27. The armature assembly can be inserted into slide piece 34 as a preassembled unit, armature pin 27 being inserted into opening 68 and crescent disk 50 at least partially penetrating recess 52. The inner contour of recess 52 secures crescent disk 50 from laterally slipping off of the armature pin. 

What is claimed is:
 1. A solenoid valve for controlling a fuel injector of an internal combustion engine, including an electromagnet (29), a movable armature featuring an armature plate (28) and an armature pin (27), as well as a control valve member (25) which moves with the armature and cooperates with a valve seat (24), for opening and closing a fuel discharge passage (17) of a control pressure chamber (14) of the fuel injector (1), the armature plate (28) being supported on the armature pin (27) in such a manner that it is slidably movable in the closing direction of the control valve member (25) under the action of its inertial mass, against the elastic force of a return spring (35) that acts upon the armature plate (28); and including a hydraulic damping device which permits damping of a post-oscillation of the armature plate (28) during its dynamic sliding on the armature pin (27), wherein the return spring (35), with its end (62) facing away from the armature plate (28), is braced against a supporting piece (50) which is mounted on and moved with the armature pin (27) and which, at the same time, constitutes a part (57) of the damping device.
 2. The solenoid valve as recited in claim 1, wherein the armature pin (27), the armature plate (28), the return spring (35), and the supporting piece (50), which is secured to the armature pin, are inserted into the solenoid valve housing (60) as a preassembled armature assembly.
 3. The solenoid valve as recited in claim 1 or 2, wherein the armature pin (27) is slidably supported in an opening (68) of a slide piece (34) which is immovably mounted in the housing (60) of the solenoid valve (30).
 4. The solenoid valve as recited in claim 3, wherein the side of the slide piece (34) facing the armature plate (28) features a recess (52) in which is positioned the supporting piece (50) which is mounted on the armature pin (27), the outer contour of the supporting piece (50) being spaced apart from the inner contour of the recess (52) by a gap.
 5. The solenoid valve as recited in claim 4, wherein the gap filled with fuel between the supporting piece (50) and the inner wall of the recess (52) forms a further damping device which permits damping of a striking of the control valve member (25) coupled to the armature pin (27) against the valve seat (24).
 6. The solenoid valve as recited in one of the claims 1 through 5, wherein the supporting piece (50) has a disk-shaped design.
 7. The solenoid valve as recited in one of the claims 1 through 6, wherein the supporting piece (50) is secured to the armature pin (27) by welding, adhesive bonding, soldering or shrink-fitting.
 8. The solenoid valve as recited in one of the claims 1 through 5, wherein the supporting piece (50) is designed as a crescent disk.
 9. The solenoid valve as recited in claim 8, wherein the supporting piece is secured in a positive-locking manner in a circumferential groove (54) of the armature pin (27).
 10. The solenoid as recited in claims 4 and 8, wherein the crescent disk (50) is laterally slid onto a section (72) of the armature pin (27) that is not guided in the slide piece (34) and is pressed by the spring force of the return spring (35) against a shoulder (71) formed on the armature pin (27) and is secured by the inner contour of the recess (52) in a radial direction, preventing it from slipping off of the armature pin. 